Methods and apparatuses for making elastomeric laminates with elastic strands unwound from beams

ABSTRACT

The present disclosure relates to methods for assembling elastomeric laminates, wherein elastic material may be stretched and joined with either or both first and second substrates. A first beam is rotated to unwind a first plurality of elastic strands from the first beam in the machine direction. The first plurality of elastic strands are positioned between the first substrate and the second substrate to form the elastomeric laminate. Before the first plurality of elastic strands are completely unwound from the first beam, a second beam is rotated to unwind the second plurality of elastic strands from the second beam. Subsequently, the advancement of the first plurality of elastic strands from the first beam is discontinued. Thus, the elastomeric laminate assembly process may continue uninterrupted while switching from an initially utilized elastic material drawn from the first beam to a subsequently utilized elastic material drawn from the second beam.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 15/831,448, filed onDec. 5, 2017, which claims the benefit, under 35 USC 119(e), to U.S.Provisional Patent Application No. 62/436,589, filed on Dec. 20, 2016;U.S. Provisional Patent Application No. 62/483,965, filed on Apr. 11,2017; U.S. Provisional Patent Application No. 62/553,149, filed on Sep.1, 2017; U.S. Provisional Patent Application No. 62/553,171, filed onSep. 1, 2017; U.S. Provisional Patent Application No. 62/553,538, filedon Sep. 1, 2017; and U.S. Provisional Patent Application No. 62/581,278,filed on Nov. 3, 2017; each of which are herein incorporated byreference in their entirety.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingelastomeric laminates that may be used as components of absorbentarticles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from an advancing web or webs are combinedwith other individual components created from other advancing webs. Websof material and component parts used to manufacture diapers may include:backsheets, topsheets, leg cuffs, waist bands, absorbent corecomponents, front and/or back ears, fastening components, and varioustypes of elastic webs and components such as leg elastics, barrier legcuff elastics, stretch side panels, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles.

Some absorbent articles have components that include elastomericlaminates. Such elastomeric laminates may include an elastic materialbonded to one or more nonwovens. The elastic material may include anelastic film and/or elastic strands. In some laminates, a plurality ofelastic strands are joined to a nonwoven while the plurality of strandsare in a stretched condition so that when the elastic strands relax, thenonwoven gathers between the locations where the nonwoven is bonded tothe elastic strands, and in turn, forms corrugations. The resultingelastomeric laminate is stretchable to the extent that the corrugationsallow the elastic strands to elongate.

In some assembly processes, stretched elastic strands may be advanced ina machine direction and adhered between two advancing substrates,wherein the stretched elastic strands are spaced apart from each otherin a cross direction. Some assembly processes are also configured withseveral elastic strands that are very closely spaced apart from eachother in the cross direction. In some configurations, close crossdirectional spacing between elastic strands can be achieved by drawingelastic strands from windings that have been stacked in the crossdirection on a beam. For example, various textile manufacturers mayutilize beam elastics and associated handling equipment, such asavailable from Karl Mayer Corporation. However, problems can beencountered in manufacturing processes when drawing elastic strandsstacked on a beam. For example, when elastic strands are completelydrawn from the beam, a new beam of elastics will be needed to replacethe empty beam. As such, in some configurations, an entire manufacturingline may need to be temporarily stopped while the empty beam isreplaced. Manufacturing lines in the textile industry often operate atrelatively slow speeds, and as such, these textile manufacturing linescan be temporarily stopped to replace an empty beam and may not resultin a major disruption to production. However, some manufacturing lines,such as disposable absorbent article manufacturing lines, may operate athigh speeds and/or would require depleted beams of elastics to bereplaced relatively often. As such, it can be inefficient and/or costprohibitive to frequently stop and restart high speed manufacturingoperations to replace empty beams.

Consequently, it would be beneficial to provide a method and apparatusfor producing elastomeric laminates with beams of elastic strands thatcan be replaced without having to stop the assembly process.

SUMMARY OF THE INVENTION

In a first aspect, a method for making an elastomeric laminate comprisesthe steps of: providing a first plurality of elastic strands wound ontoa first beam; providing a second plurality of elastic strands wound ontoa second beam; rotating a first roller about a first axis of rotationextending in a cross direction, the first roller comprising an outercircumferential surface comprising a surface speed V1; rotating a secondroller about a second axis of rotation extending in the cross direction,the second roller comprising an outer circumferential surface comprisinga surface speed V1, wherein the first roller and the second rollerrotate in opposite directions, and wherein the first roller is adjacentthe second roller to define a nip between the first roller and thesecond roller; advancing a first substrate and a second substratethrough the nip; rotating the first beam to unwind the first pluralityof elastic strands from the first beam in a machine direction at a speedV2, wherein the first plurality of elastic strands are separated fromeach other in the cross direction, and wherein V2 is less than V1;stretching the first plurality of elastic strands in the machinedirection by advancing the first plurality of elastic strands from thefirst beam through the nip and between the first substrate and thesecond substrate; connecting the second plurality of elastic strandswith a splicer member; rotating the second beam to unwind the secondplurality of elastic strands from the second beam in the machinedirection, wherein the second plurality of elastic strands are separatedfrom each other in the cross direction; advancing the splicer member andthe second plurality of elastic strands through the nip; anddiscontinuing advancement of the first plurality of elastic strandsthrough the nip subsequent to advancing the splicer member through thenip.

In another aspect, a method for making an elastomeric laminate comprisesthe steps of: providing a first plurality of elastic strands wound ontoa first beam; providing a second plurality of elastic strands wound ontoa second beam; rotating a first roller about a first axis of rotationextending in a cross direction, the first roller comprising an outercircumferential surface comprising a surface speed V1; providing a firstsubstrate comprising a first surface and an opposing second surface;advancing the first surface of the first substrate onto the outercircumferential surface of the first roller; rotating the first beam tounwind the first plurality of elastic strands from the first beam in amachine direction at a speed V2, wherein the first plurality of elasticstrands are separated from each other in the cross direction, andwherein V2 is less than V1; stretching the first plurality of elasticstrands in the machine direction by advancing the first plurality ofelastic strands from the first beam onto second surface of the firstsubstrate; advancing the combined first substrate and the firstplurality of elastic strands in the machine direction from the firstroller; connecting the second plurality of elastic strands with asplicer member; rotating the second beam to unwind the second pluralityof elastic strands from the second beam in the machine direction,wherein the second plurality of elastic strands are separated from eachother in the cross direction; combining the splicer member and thesecond plurality of elastic strands with the first plurality of elasticstrands on the second surface of the first substrate; and subsequentlydiscontinuing advancement of the first plurality of elastic strands ontothe second surface of the first substrate.

In yet another aspect, a method for making an elastomeric laminatecomprises the steps of: providing a first plurality of elastic strandswound onto a first beam; providing a second plurality of elastic strandswound onto a second beam; rotating a roller about a first axis ofrotation extending in a cross direction, the roller comprising an outercircumferential surface; providing a first substrate and a secondsubstrate, each comprising a first surface and an opposing secondsurface; advancing the first surface of the first substrate onto theouter circumferential surface of the roller; rotating the first beam tounwind the first plurality of elastic strands from the first beam in amachine direction, wherein the first plurality of elastic strands areseparated from each other in the cross direction; stretching the firstplurality of elastic strands in the machine direction while advancingthe first plurality of elastic strands from the first beam onto thesecond surface of the first substrate; advancing the first surface ofthe second substrate onto the second surface of the first substrate suchthat the first plurality of elastic strands and the first substrate arepositioned between the second substrate and the outer circumferentialsurface of the roller; advancing the combined first substrate, secondsubstrate, and the first plurality of elastic strands in the machinedirection from the roller; rotating the second beam to unwind the secondplurality of elastic strands from the second beam in the machinedirection, wherein the second plurality of elastic strands are separatedfrom each other in the cross direction; advancing the second pluralityof elastic strands in between the second surface of the first substrateand the first surface of the second substrate such that the firstplurality of elastic strands, the second plurality of elastic strands,and the first substrate are positioned between the second substrate andthe outer circumferential surface of the roller; and subsequentlydiscontinuing advancement of the first plurality of elastic strands ontothe second surface of the first substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of a diaper pant.

FIG. 1B is a rear perspective view of a diaper pant.

FIG. 2 is a partially cut away plan view of the diaper pant shown inFIGS. 1A and 1B in a flat, uncontracted state.

FIG. 3A is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3B-3B.

FIG. 4 is a schematic side view of a converting apparatus adapted tomanufacture an elastomeric laminate including a first plurality ofelastic strands positioned between a first substrate and a secondsubstrate.

FIG. 5 is a view of the converting apparatus of FIG. 4 taken along line5-5.

FIG. 6 is a view of the converting apparatus of FIG. 4 taken along line6-6.

FIG. 7 is a schematic side view of the converting apparatus of FIG. 4showing a second plurality of elastic strands connected with a firstplurality of elastic strands upstream of a nip.

FIG. 8 is a schematic side view of the converting apparatus of FIG. 4showing the first and second plurality of elastic strands advancingthrough the nip.

FIG. 9 is a view of the converting apparatus of FIG. 8 taken along line9-9.

FIG. 10 is a view of the converting apparatus of FIG. 8 taken along line10-10.

FIG. 11 is a schematic side view of the converting apparatus of FIG. 4assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

FIG. 12 is a view of the converting apparatus of FIG. 11 taken alongline 12-12.

FIG. 13 is a schematic side view of the converting apparatus of FIG. 4showing the second plurality of elastic strands connected with the firstsubstrate upstream of a nip.

FIG. 14 is a schematic side view of a second configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a first plurality of elastic strands positioned between afirst substrate and a second substrate.

FIG. 15 is a schematic side view of the converting apparatus of FIG. 14showing a second plurality of elastic strands connected with a firstplurality of elastic strands upstream of a first roller.

FIG. 16 is a schematic side view of the converting apparatus of FIG. 14showing the first and second plurality of elastic strands advancing ontothe first substrate.

FIG. 17 is a schematic side view of the converting apparatus of FIG. 14assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

FIG. 18 is a schematic side view of the converting apparatus of FIG. 14showing the second plurality of elastic strands connected with the firstsubstrate upstream of the first roller.

FIG. 19 is a schematic side view of a third configuration of aconverting apparatus adapted to manufacture an elastomeric laminateincluding a first plurality of elastic strands positioned between afirst substrate and a second substrate.

FIG. 20 is a schematic side view of the converting apparatus of FIG. 19assembling the elastomeric laminate with the first and second pluralityof elastic strands advancing between the first and second substrates.

FIG. 21 is a schematic side view of the converting apparatus of FIG. 19assembling the elastomeric laminate showing the trailing ends of thefirst plurality of elastic strands advancing between the first andsecond substrates.

FIG. 22 is a schematic side view of the converting apparatus of FIG. 19assembling the elastomeric laminate with the second plurality of elasticstrands positioned between the first and second substrates.

FIG. 23 is a schematic side view of a converting apparatus adapted tomanufacture an elastomeric laminate.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure: “Absorbent article” is used herein to refer toconsumer products whose primary function is to absorb and retain soilsand wastes. “Diaper” is used herein to refer to an absorbent articlegenerally worn by infants and incontinent persons about the lower torso.The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as an absorbent article (e.g., they are intended to bediscarded after a single use and may also be configured to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations in U.S. Pat. Nos. 5,167,897, 5,360,420,5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537,6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787,6,617,016, 6,825,393, and 6,861,571; and U.S. Patent Publication Nos.2013/0072887 A1; 2013/0211356 A1; and 2013/0306226 A1, all of which areincorporated by reference herein.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, to methods for making elastomeric laminatesthat may be used as components of absorbent articles. The elastomericlaminates may include a first substrate, a second substrate, and anelastic material located between the first substrate and secondsubstrate. During the process of making the elastomeric laminate, theelastic material may be advanced and stretched in a machine directionand may be joined with either or both the first and second substratesadvancing in the machine direction.

The methods and apparatuses according to the present disclosure may beconfigured with a first plurality of elastic strands wound onto a firstbeam and a second plurality of elastic strands wound onto a second beam.During assembly of an elastomeric laminate, a first substrate isadvanced onto the outer circumferential surface of the roller that isrotating about a first axis of rotation extending in a cross direction.The first beam is rotated to unwind the first plurality of elasticstrands from the first beam in the machine direction. The firstplurality of elastic strands may be stretched in the machine directionwhile advancing from the first beam onto the first substrate. A secondsubstrate advances onto the first substrate such that the firstplurality of elastic strands are positioned between the first substrateand the second substrate to form the elastomeric laminate. Before thefirst plurality of elastic strands are completely unwound from the firstbeam, the second beam is rotated to unwind the second plurality ofelastic strands from the second beam in the machine direction, whereinthe second plurality of elastic strands are separated from each other inthe cross direction. The second plurality of elastic strands areadvanced in the machine direction from the second beam to between thefirst substrate and the second substrate such that the first andplurality of elastic strands are positioned between the first and secondsubstrates. Subsequently, the advancement of the first plurality ofelastic strands from the first beam is discontinued. As such, theelastomeric laminate assembly process may continue uninterrupted whileswitching from an initially utilized elastic material drawn from thefirst beam to a subsequently utilized elastic material drawn from thesecond beam.

As previously mentioned, the elastomeric laminates made according to theprocesses and apparatuses discussed herein may be used to constructvarious types of components used in the manufacture of different typesof absorbent articles, such as diaper pants and taped diapers. To helpprovide additional context to the subsequent discussion of the processembodiments, the following provides a general description of absorbentarticles in the form of diapers that include components including theelastomeric laminates that may be produced with the methods andapparatuses disclosed herein.

FIGS. 1A, 1B, and 2 show an example of a diaper pant 100 that mayinclude components constructed from elastomeric laminates assembled inaccordance with the apparatuses and methods disclosed herein. Inparticular, FIGS. 1A and 1B show perspective views of a diaper pant 100in a pre-fastened configuration, and FIG. 2 shows a plan view of thediaper pant 100 with the portion of the diaper that faces away from awearer oriented toward the viewer. The diaper pant 100 includes achassis 102 and a ring-like elastic belt 104. As discussed below in moredetail, a first elastic belt 106 and a second elastic belt 108 arebonded together to form the ring-like elastic belt 104.

With continued reference to FIG. 2, the diaper pant 100 and the chassis102 each include a first waist region 116, a second waist region 118,and a crotch region 119 disposed intermediate the first and second waistregions. The first waist region 116 may be configured as a front waistregion, and the second waist region 118 may be configured as back waistregion.

The diaper 100 may also include a laterally extending front waist edge121 in the front waist region 116 and a longitudinally opposing andlaterally extending back waist edge 122 in the back waist region 118. Toprovide a frame of reference for the present discussion, the diaper 100and chassis 102 of FIG. 2 are shown with a longitudinal axis 124 and alateral axis 126. In some embodiments, the longitudinal axis 124 mayextend through the front waist edge 121 and through the back waist edge122. And the lateral axis 126 may extend through a first longitudinal orright side edge 128 and through a midpoint of a second longitudinal orleft side edge 130 of the chassis 102.

As shown in FIGS. 1A, 1B, and 2, the diaper pant 100 may include aninner, body facing surface 132, and an outer, garment facing surface134. The chassis 102 may include a backsheet 136 and a topsheet 138. Thechassis 102 may also include an absorbent assembly 140, including anabsorbent core 142, disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 121 andthe back waist edge 122 may encircle a portion of the waist of thewearer. At the same time, the side edges 128 and 130 may encircle atleast a portion of the legs of the wearer. And the crotch region 119 maybe generally positioned between the legs of the wearer with theabsorbent core 142 extending from the front waist region 116 through thecrotch region 119 to the back waist region 118.

As previously mentioned, the diaper pant 100 may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may also comprise a woven or nonwovenmaterial, polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material. The backsheet may also comprise anelastomeric film. An example backsheet 136 may be a polyethylene filmhaving a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm(2.0 mils). Further, the backsheet 136 may permit vapors to escape fromthe absorbent core (i.e., the backsheet is breathable) while stillpreventing exudates from passing through the backsheet 136.

Also described above, the diaper pant 100 may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be liquid pervious, permittingliquids (e.g., menses, urine, and/or runny feces) to penetrate throughits thickness. A topsheet 138 may be manufactured from a wide range ofmaterials such as woven and nonwoven materials; apertured or hydroformedthermoplastic films; apertured nonwovens, porous foams; reticulatedfoams; reticulated thermoplastic films; and thermoplastic scrims. Wovenand nonwoven materials may comprise natural fibers such as wood orcotton fibers; synthetic fibers such as polyester, polypropylene, orpolyethylene fibers; or combinations thereof. If the topsheet 138includes fibers, the fibers may be spunbond, carded, wet-laid,meltblown, hydroentangled, or otherwise processed as is known in theart. Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Exemplaryapertured films may include those described in U.S. Pat. Nos. 5,628,097;5,916,661; 6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100 may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2, theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprise primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper 100 may also include elasticized legcuffs 156. It is to be appreciated that the leg cuffs 156 can be and aresometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730 A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIGS. 1A and 1B.The ring-like elastic belt may be formed by joining a first elastic beltto a second elastic belt with a permanent side seam or with an openableand reclosable fastening system disposed at or adjacent the laterallyopposing sides of the belts.

As previously mentioned, the ring-like elastic belt 104 may be definedby a first elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2, the first elastic belt 106 extends between a firstlongitudinal side edge 111 a and a second longitudinal side edge 111 band defines first and second opposing end regions 106 a, 106 b and acentral region 106 c. And the second elastic 108 belt extends between afirst longitudinal side edge 113 a and a second longitudinal side edge113 b and defines first and second opposing end regions 108 a, 108 b anda central region 108 c. The distance between the first longitudinal sideedge 111 a and the second longitudinal side edge 111 b defines the pitchlength, PL, of the first elastic belt 106, and the distance between thefirst longitudinal side edge 113 a and the second longitudinal side edge113 b defines the pitch length, PL, of the second elastic belt 108. Thecentral region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIGS. 1A and 1B, the first endregion 106 a of the first elastic belt 106 is connected with the firstend region 108 a of the second elastic belt 108 at first side seam 178,and the second end region 106 b of the first elastic belt 106 isconnected with the second end region 108 b of the second elastic belt108 at second side seam 180 to define the ring-like elastic belt 104 aswell as the waist opening 110 and leg openings 112.

As shown in FIGS. 2, 3A, and 3B, the first elastic belt 106 also definesan outer laterally extending edge 107 a and an inner laterally extendingedge 107 b, and the second elastic belt 108 defines an outer laterallyextending edge 109 a and an inner laterally extending edge 109 b. Assuch, a perimeter edge 112 a of one leg opening may be defined byportions of the inner laterally extending edge 107 b of the firstelastic belt 106, the inner laterally extending edge 109 b of the secondelastic belt 108, and the first longitudinal or right side edge 128 ofthe chassis 102. And a perimeter edge 112 b of the other leg opening maybe defined by portions of the inner laterally extending edge 107 b, theinner laterally extending edge 109 b, and the second longitudinal orleft side edge 130 of the chassis 102. The outer laterally extendingedges 107 a, 109 a may also define the front waist edge 121 and thelaterally extending back waist edge 122 of the diaper pant 100. Thefirst elastic belt and the second elastic belt may also each include anouter, garment facing layer 162 and an inner, wearer facing layer 164.It is to be appreciated that the first elastic belt 106 and the secondelastic belt 108 may comprise the same materials and/or may have thesame structure. In some embodiments, the first elastic belt 106 and thesecond elastic belt may comprise different materials and/or may havedifferent structures. It should also be appreciated that the firstelastic belt 106 and the second elastic belt 108 may be constructed fromvarious materials. For example, the first and second belts may bemanufactured from materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers) or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. In someembodiments, the first and second elastic belts include a nonwoven webof synthetic fibers, and may include a stretchable nonwoven. In otherembodiments, the first and second elastic belts include an innerhydrophobic, non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer substrate layer 162 andthe inner substrate layer 164. The belt elastic material may include oneor more elastic elements such as strands, ribbons, films, or panelsextending along the lengths of the elastic belts. As shown in FIGS. 2,3A, and 3B, the belt elastic material may include a plurality of elasticstrands 168 which may be referred to herein as outer, waist elastics 170and inner, waist elastics 172. Elastic strands 168, such as the outerwaist elastics 170, may continuously extend laterally between the firstand second opposing end regions 106 a, 106 b of the first elastic belt106 and between the first and second opposing end regions 108 a, 108 bof the second elastic belt 108. In some embodiments, some elasticstrands 168, such as the inner waist elastics 172, may be configuredwith discontinuities in areas, such as for example, where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, the elastic strands 168 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 168 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt. It is to be appreciated that thechassis 102 and elastic belts 106, 108 may be configured in differentways other than as depicted in FIG. 2. The belt elastic material may bejoined to the outer and/or inner layers continuously or intermittentlyalong the interface between the belt elastic material and the innerand/or outer belt layers.

In some configurations, the first elastic belt 106 and/or second elasticbelt 108 may define curved contours. For example, the inner lateraledges 107 b, 109 b of the first and/or second elastic belts 106, 108 mayinclude non-linear or curved portions in the first and second opposingend regions. Such curved contours may help define desired shapes to legopening 112, such as for example, relatively rounded leg openings. Inaddition to having curved contours, the elastic belts 106, 108 mayinclude elastic strands 168, 172 that extend along non-linear or curvedpaths that may correspond with the curved contours of the inner lateraledges 107 b, 109 b.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various components of diapers, such as elasticbelts, leg cuffs, and the like. For example, FIGS. 4-23 show schematicviews of converting apparatuses 300 adapted to manufacture elastomericlaminates 302. As described in more detail below, the convertingapparatuses 300 shown in FIGS. 4-23 operate to advance a continuouslength of elastic material 304, a continuous length of a first substrate306, and a continuous length of a second substrate 308 along a machinedirection MD. It is also to be appreciated that in some configurations,the first substrate and second substrate 306, 308 herein may be definedby two discrete substrates or may be defined by folded portions of asingle substrate. The apparatus 300 stretches the elastic material 304and joins the stretched elastic material 304 with the first and secondsubstrates 306, 308 to produce an elastomeric laminate 302. Although theelastic material 304 is illustrated and referred to herein as strands,it is to be appreciated that elastic material 304 may include one ormore continuous lengths of elastic strands, ribbons, and/or films.

The elastomeric laminates 302 can be used to construct various types ofdiaper components. For example, the elastomeric laminates 302 may beused as a continuous length of elastomeric belt material that may beconverted into the first and second elastic belts 106, 108 discussedabove with reference to FIGS. 1-3B. As such, the elastic material 304may correspond with the belt elastic material 168 interposed between theouter layer 162 and the inner layer 164, which in turn, may correspondwith either the first and/or second substrates 306, 308. In otherexamples, the elastomeric laminates may be used to construct waistbandsand/or side panels in taped diaper configurations. In yet otherexamples, the elastomeric laminates may be used to construct varioustypes of leg cuff and/or topsheet configurations.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a firstrotating beam to a downstream metering device to be joined with one ormore advancing substrates. Before the elastic material is completelydrawn from or removed from the first beam, elastic material may also beadvanced in the machine direction from a second rotating beam to thedownstream metering device to be joined with one or more advancingsubstrates. Subsequently, advancement of the elastic material from thefirst beam to the downstream metering device may be discontinued. Assuch, the elastomeric laminate assembly process continues uninterruptedwhile replacing elastic material unwound from the first beam withelastic material unwound from the second beam. Thus, the empty firstbeam may be replaced with another beam with elastic material woundthereon without interrupting and/or stopping the assembly of theelastomeric laminate.

As shown in FIGS. 4-6, a converting apparatus 300 for producing anelastomeric laminate 302 may include a first metering device 310, asecond metering device 312, and a third metering device 314. The firstmetering device may be configured as a first beam 316 with a firstplurality of elastic strands 318 wound thereon, and the third meteringdevice is configured as a second beam 320 with a second plurality ofelastic strands 322 wound thereon. FIG. 10 shows an example of an emptybeam 316 that includes two side plates 317 a, 317 b that may beconnected with opposing end portions of a mandrel core 319, whereinelastic strands may be wound onto the mandrel core 319. It is to beappreciated that beams of various sizes and technical specifications maybe utilized in accordance with the methods and apparatuses herein, suchas for example, beams that are available from ALUCOLOR Textilmaschinen,GmbH. During operation, the first plurality of elastic strands 318advance in the machine direction MD from the first beam 316 to thesecond metering device 312. In addition, the first plurality of elasticstrands 318 may be stretched along the machine direction MD between thefirst beam 316 and the second metering device 312. The stretched firstelastic strands 318 are also joined with a first substrate 306 and asecond substrate 308 at the second metering device 312 to produce anelastomeric laminate 302. As discussed in more detail below, once thefirst beam 316 is empty or nearly depleted of first elastic strands 318,the second plurality of elastic strands 322 can be introduced into theassembly operation as replacements for the first plurality of elasticstands 318 without having to stop the assembly operation.

As shown in FIG. 4, the second metering device 312 includes: a firstroller 324 having an outer circumferential surface 326 and rotates abouta first axis of rotation 328, and a second roller 330 having an outercircumferential surface 332 and rotates about a second axis of rotation334. The first roller 324 and the second roller 330 rotate in oppositedirections, and the first roller 324 is adjacent the second roller 330to define a nip 336 between the first roller 324 and the second roller330. The first roller 324 rotates such that the outer circumferentialsurface 326 has a surface speed V1, and the second roller 330 may rotatesuch that the outer circumferential surface 332 has the same, orsubstantially the same, surface speed V1.

As shown in FIGS. 4 and 5, the first substrate 306 includes a firstsurface 338 and an opposing second surface 340, and the first substrate306 advances to the first roller 324. In particular, the first substrate306 advances at speed V1 to the first roller 324 where the firstsubstrate 306 partially wraps around the outer circumferential surface326 of the first roller 324 and advances through the nip 336. As such,the first surface 338 of the first substrate 306 travels in the samedirection as and in contact with the outer circumferential surface 326of the first roller 324. In addition, the second substrate 308 includesa first surface 342 and an opposing second surface 344, and the secondsubstrate 308 advances to the second roller 330. In particular, thesecond substrate 308 advances at speed V1 to the second roller 330 wherethe second substrate 308 partially wraps around the outercircumferential surface 332 of the second roller 330 and advancesthrough the nip 336. As such, the second surface 344 of the secondsubstrate 308 travels in the same direction as and in contact with theouter circumferential surface 332 of the second roller 330.

With continued reference to FIGS. 4 and 5, the first beam 316 includesthe first plurality of elastic strands 318 wound thereon, and the firstbeam 316 is rotatable about a first beam rotation axis 346. In someconfigurations, the first beam rotation axis 346 may extend in the crossdirection CD. As the first beam 316 rotates, the first plurality ofelastic strands 318 advance from the first beam 316 at a speed V2 withthe first elastic strands 318 being spaced apart from each other in thecross direction CD. From the first beam 316, the first plurality ofelastic strands 318 advances in the machine direction MD to the nip 336.In some configurations, the speed V2 is less than the speed V1, and assuch, the first plurality of elastic strands 318 are stretched in themachine direction MD. In turn, the stretched first elastic strands 318advance through the nip 336 between the first and second substrates 306,308 such that the first elastic strands 318 are joined with the secondsurface 340 of the first substrate 306 and the first surface 342 of thesecond substrate 308 to produce a continuous length of elastomericlaminate 302. As shown in FIG. 4, the first substrate 306 may advancepast an adhesive applicator device 348 that applies adhesive 350 to thesecond surface 340 of the first substrate 306 before advancing to thenip 336. It is to be appreciated that the adhesive 350 may be applied tothe first substrate 306 upstream of the first roller 324 and/or whilethe first substrate 306 is partially wrapped around the outercircumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may be applied to the first elastic strands318 before and/or while being joined with first substrate 306 and secondsubstrate 308. In addition, it is to be appreciated that adhesive may beapplied to the first surface 342 of the second substrate 308 before orwhile being joined with the first elastic strands 318 and the firstsubstrate 306.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 322 configured to replace the first plurality ofelastic stands 318 once the first beam 316 is completely depleted ornearly depleted of first elastic strands 318. As shown in FIGS. 4 and 6,the second beam 320 includes the second plurality of elastic strands 322wound thereon, and the second beam 320 is rotatable about a second beamrotation axis 352. In some configurations, the second beam rotation axis352 may extend in the cross direction CD. As the second beam 320rotates, the second plurality of elastic strands 322 advance from thesecond beam 320 at a speed V2 with the second elastic strands 322 beingspaced apart from each other in the cross direction CD. When introducingthe second elastic strands 322 into the assembly operation, the secondplurality of elastic strands 322 may first be connected with a splicermember 354. As shown in FIG. 6, the splicer member 354 may be connectedadjacent leading ends 356 of the second elastic strands 322. In turn,the splicer member 354 and the second elastic strands 322 may beconnected with the first plurality of elastic strands 318 that areadvancing from the first beam 316 to the nip 336 as shown in FIG. 7. Asshown in FIGS. 8 and 9, the splicer member 354 and the leading ends 356of the second plurality of elastic strands 322 advance in the machinedirection MD and are positioned between the first and second substrates306, 308 along with the first plurality of elastic strands 318. Once thesecond elastic strands 322 are combined with the first substrate 306and/or second substrate 308, advancement of the first plurality ofelastic strands 318 from the first beam 316 may be discontinued. In someinstances, advancement of the first plurality of elastic strands 318from the first beam 316 may be discontinued as a result of the firstelastic strands 318 being completely unwound from the first beam 316such that trailing ends 358 of the first elastic strands 318 advancethrough the nip 336 such as shown in FIGS. 8-10. In some configurations,the first elastic strands 318 may be cut to discontinue advancement fromthe first beam 316.

As shown in FIGS. 11 and 12, the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastics 322 on the second beam 320. As the second beam 320 rotates, thesecond plurality of elastic strands 322 advance from the second beam 320at a speed V2 with the second elastic strands 322 being spaced apartfrom each other in the cross direction CD. From the second beam 320, thesecond plurality of elastic strands 322 advances in the machinedirection MD to the nip 336. In some configurations, the speed V2 isless than the speed V1, and as such, the second plurality of elasticstrands 322 are stretched in the machine direction MD. In turn, thestretched second elastic strands 322 advance through the nip 336 betweenthe first and second substrates 306, 308 such that the second elasticstrands 322 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce the continuous length of elastomeric laminate 302. Thus, thesecond plurality of elastic strands 322 can be introduced into theassembly operation as replacements for the first plurality of elasticstands 318 without having to stop rotation of the first beam 316 andwithout having to stop the elastomeric laminate 302 assembly operation.In turn, the empty first beam 316, such as shown in FIG. 10, can bereplaced with a beam having a plurality of elastics wound thereonpositioned to replace the second plurality of elastics 322 once depletedfrom the second beam 320.

It is to be appreciated that the apparatus 300 can be configured tooperate in various ways to advance the leading ends 356 of the secondplurality of elastics 322 between the first and second substrates 306,308. For example, the splicer member 354 discussed above with referenceto FIG. 6 may include one or more tacky surfaces 360 adapted to adhereto the second plurality of elastic strands 322. In addition, the one ormore tacky surfaces 360 also adhere the splicer member 354 with theadvancing first plurality of elastic strands 318 as described above withreference to FIGS. 7-9. It is also to be appreciated that the splicermember 354 may be connected with the first elastic strands 318 withadhesive applied to the first elastic strands 318 upstream of the nip336. It is also to be appreciated that in some configurations of theapparatus 300, the second elastic strands 322 may be introduced into theassembly operation without having to connect the second elastic strands322 with a splicer member 354.

In some configurations, as opposed to being connected with the firstelastic strands 318, the splicer member 354 and/or second elasticstrands 322 may be connected with the first substrate 306 or the secondsubstrate 308 upstream of the nip 336. For example, as shown in FIG. 13,after second elastic strands 322 are connected with the splicer member354, the splicer member 354 may be connected with the second surface 340of the first substrate 306. As discussed above, the splicer member 354may include a tacky surface 360 that adheres to the first substrate 306and/or may be adhered to the first substrate with adhesive 350. Once thesplicer member 354 is connected with the first substrate 306, thesplicer member 354 and second elastic strands 322 advance along with thefirst substrate 306 through the nip 336.

It is to be appreciated that different components may be used toconstruct the elastomeric laminates 302 in accordance with the methodsand apparatuses herein. For example, the first and/or second substrates306, 308 may include nonwovens and/or films. In addition, the firstand/or second elastic strands 318, 322 may be configured in various waysand having various decitex values. In some configurations, the firstand/or second plurality of elastic strands 318, 322 may be configuredwith decitex values ranging from about 10 decitex to about 500 decitex,specifically reciting all 1 decitex increments within the above-recitedrange and all ranges formed therein or thereby. It is also to beappreciated the first beam 316 and the second beam 320 may be configuredin various ways and with various quantities of elastic strands. Examplebeams, also referred to as warp beams, that may be used with theapparatus and methods herein are disclosed in U.S. Pat. Nos. 4,525,905;5,060,881; and 5,775,380; and U.S. Patent Publication No. 2004/0219854A1. Although FIG. 5 shows nine elastic strands 318 advancing from thefirst beam 316, it is to be appreciated that the apparatuses herein maybe configured such that more or less than nine elastic strands 318advance from the first beam 316. And although FIG. 6 shows nine elasticstrands 322 advancing from the second beam 320, it is to be appreciatedthat the apparatuses herein may be configured such that more or lessthan nine elastic strands 322 advance from the second beam 320. In someconfigurations, the first elastic strands 318 advancing from the firstbeam 316 and/or the second elastic strands 322 advancing from the secondbeam 320 may include from about 100 to about 2000 strands, specificallyreciting all 1 strand increments within the above-recited range and allranges formed therein or thereby. In some configurations, the firstelastic strands 318 and/or the second elastic strands 322 may beseparated from each other by about 0.5 mm to about 4 mm in the crossdirection, specifically reciting all 0.1 mm increments within theabove-recited range and all ranges formed therein or thereby. Asdiscussed herein, the elastics in the plurality of elastic strands maybe pre-strained prior to joining the elastic strand to the first orsecond substrate layers 306, 308. In some configurations, the elasticmay be pre-strained from about 75% to about 300%, specifically recitingall 1% increments within the above-recited range and all ranges formedtherein or thereby. It is also to be appreciated that one or more beamsof elastics may be arranged along the cross direction CD of a convertingprocess and/or arranged along a machine direction MD in variousdifferent portions of a converting process. It is also to be appreciatedthat the first beam 316 and the second beam 320 can be connected withone or more motors, such as servo motors, to drive and control therotation of the beams 316, 320.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302 having various stretchcharacteristics. For example, the apparatus 300 may be configured toassemble elastomeric laminates 302 with elastic strands 318, 322 unwoundfrom more than one beam and/or in combination with elastic standssupplied from an overend unwinder. The elastic strands may be joinedwith the first and second substrates 306, 308 such that the elastomericlaminate 302 may have different stretch characteristics in differentregions along the cross direction CD. For example, when the elastomericlaminate 302 is elongated, some elastic strands may exert contractionforces in the machine direction MD that are different from contractionforces exerted by other elastic strands. Such differential stretchcharacteristics can be achieved by stretching some elastic strands moreor less than other elastic strands before joining the elastic strandswith the first and second substrates 306, 308. It is also to beappreciated that the elastic strands may have various different materialconstructions and/or decitex values to create elastomeric laminates 302having different stretch characteristics in different regions. In someconfigurations, the elastomeric laminate may have regions where theelastic strands are spaced relatively close to one another in the crossdirection CD and other regions where the elastic strands are spacedrelatively farther apart from each other in the cross direction CD tocreate different stretch characteristics in different regions. In someconfigurations, the elastic strands may be supplied on the beam in astretched state, and as such, may not require additional stretching (ormay require relatively less additional stretching) before being combinedwith the first substrate 306 and/or the second substrate 308.

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways. For example, in a second configuration ofthe apparatus 300 shown in FIG. 14, the second roller 330 may bepositioned downstream from the first roller 324. As such, the firstroller 324 may be configured as the second metering device 312 and thesecond roller 330 may be configured as a fourth metering device 362. Asshown in FIG. 14, the first substrate 306 advances at speed V1 to thefirst roller 324 where the first substrate 306 partially wraps aroundthe outer circumferential surface 326 of the first roller 324 andadvances from the first roller to the second roller 330 to be combinedwith second substrate 308. As the first beam 316 rotates, the firstplurality of elastic strands 318 advance from the first beam 316 at aspeed V2 with the first elastic strands 318 being spaced apart from eachother in the cross direction CD. From the first beam 316, the firstplurality of elastic strands 318 advances in the machine direction MD tothe first roller 324 and are positioned on the second surface 340 of thefirst substrate 306. In some configurations, the speed V2 is less thanthe speed V1, and as such, the first plurality of elastic strands 318are stretched in the machine direction MD.

With continued reference to FIG. 14, the first substrate 306 and thefirst plurality of elastic strands 318 advance from the outercircumferential surface 326 of the first roller 324 to the second roller330. In addition, the second substrate 308 advances at speed V1 to thesecond roller 330 where the second substrate 308 partially wraps aroundthe outer circumferential surface 332 of the second roller 330. In turn,the combined first substrate 306 and the stretched first elastic strands318 advance from first roller 324 to the second roller 330 and arecombined with the second substrate 308 such that the first elasticstrands 318 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302. As discussedabove, the first substrate 306 may advance past an adhesive applicatordevice 348 that applies adhesive 350 to the second surface 340 of thefirst substrate 306 while advancing to the first roller 324. It is to beappreciated that the adhesive 350 may be applied to the first substrate306 while the first substrate 306 is partially wrapped around the outercircumferential surface 326 of the first roller 324. It is to beappreciated that adhesive may also be applied to the first elasticstrands 318 before and/or while being joined with first substrate 306and second substrate 308. In addition, it is to be appreciated thatadhesive may be applied to the first surface 342 of the second substrate308 before or while being joined with the first elastic strands 318 andfirst substrate 306.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 322 configured to replace the first plurality ofelastic stands 318 once the first beam 316 is completely depleted ornearly depleted of first elastic strands 318. As shown in FIGS. 14 and15, as the second beam 320 rotates, the second plurality of elasticstrands 322 advance from the second beam 320 at a speed V2 with thesecond elastic strands 322 being spaced apart from each other in thecross direction CD. As discussed above, the second plurality of elasticstrands 322 may first be connected with a splicer member 354. In turn,the splicer member 354 and the second elastic strands 322 may beconnected with the first plurality of elastic strands 318 that areadvancing from the first beam 316 to the first roller 324, as shown inFIG. 15. As shown in FIG. 15, the splicer member 354 and the leadingends 356 of the second plurality of elastic strands 322 advance in themachine direction MD and are positioned on the second surface 340 of thefirst substrate 306 on the first roller 324. From the first roller 324,the combined first substrate 306, first elastic strands 318, secondelastic strands 322, and splicer member 354 advance to the second roller330 and are positioned between the first and second substrates 306, 308.Once the second elastic strands 322 are combined with the firstsubstrate 306 and/or second substrate 308, advancement of the firstplurality of elastic strands 318 from the first beam 316 may bediscontinued wherein trailing ends 358 of the first elastic strands 318advance downstream to the first and second rollers 324, 330, such asshown in FIG. 16.

As shown in FIGS. 16 and 17, the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastic strands 322 advancing from the second beam 320. As the secondbeam 320 rotates, the second plurality of elastic strands 322 advancefrom the second beam 320 at a speed V2 with the second elastics strands322 being spaced apart from each other in the cross direction CD. Fromthe second beam 320, the second plurality of elastic strands 322advances in the machine direction MD to the first roller 324 and arepositioned on the second surface 340 of the first substrate 306. In someconfigurations, the speed V2 is less than the speed V1, and as such, thesecond plurality of elastic strands 322 are stretched in the machinedirection MD. In turn, the stretched second elastic strands 322 advancefrom the first roller 324 to the second roller 330 such that the secondelastic strands 322 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce the continuous length of elastomeric laminate 302.

As discussed above and as shown in FIG. 18, as opposed to beingconnected with the first elastic strands 318, the splicer member 354 andthe second elastic strands 322 may be connected with the first substrate306 upstream of the first roller 306. Once the splicer member 354 isconnected with the first substrate 306, the splicer member 354 andsecond elastic strands 322 advance along with the first substrate 306 tothe first roller 306 and the second roller 330 to assemble theelastomeric laminate 302.

As previously mentioned, the second elastic strands 322 may beintroduced into the assembly operation without having to connect thesecond elastic strands 322 with a splicer member 354. Thus, the secondelastic strands 322 may be connected directly with the first substrate306. It is also to be appreciated that the splicer member 354 and/or thesecond elastic strands 322 may be connected with the first substrate 306while partially wrapped around the outer circumferential surface 326 ofthe first roller 306. It is also to be appreciated that the splicermember 354 and/or the second elastic strands 322 may be connected withthe second substrate 308 upstream of the second roller 330 or whilepartially wrapped around the outer circumferential surface 332 of thesecond roller 330.

In a third configuration shown in FIG. 19, the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330. As such, the first roller 324 may be configured as the secondmetering device 312. As shown in FIG. 19, the first substrate 306advances at speed V1 to the first roller 324 where the first substrate306 partially wraps around the outer circumferential surface 326 of thefirst roller 324. While partially wrapped around the outercircumferential surface 326 of the first roller 324, the first substrate306 is combined with the first elastic strands 318 and the secondsubstrate 308. As the first beam 316 rotates, the first plurality ofelastic strands 318 advance from the first beam 316 at a speed V2 withthe first elastic strands 318 being spaced apart from each other in thecross direction CD. From the first beam 316, the first plurality ofelastic strands 318 advances in the machine direction MD to the firstroller 324 and are positioned on the second surface 340 of the firstsubstrate 306. In some configurations, the speed V2 is less than thespeed V1, and as such, the first plurality of elastic strands 318 arestretched in the machine direction MD.

With continued reference to FIG. 19, the second substrate 308 advancesat speed V1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedfirst elastic strands 318 while on the first roller 324 such that thefirst elastic strands 318 are joined with the second surface 340 of thefirst substrate 306 and the first surface 342 of the second substrate308 to produce a continuous length of elastomeric laminate 302. Asdiscussed above, the first substrate 306 may advance past an adhesiveapplicator device 348 that applies adhesive 350 to the second surface340 of the first substrate 306 while advancing to the first roller 324.It is to be appreciated that the adhesive 350 may be applied to thefirst substrate 306 while the first substrate 306 is partially wrappedaround the outer circumferential surface 326 of the first roller 324. Itis to be appreciated that adhesive may also be applied to the firstelastic strands 318 before and/or while being joined with firstsubstrate 306 and second substrate 308. In addition, it is to beappreciated that adhesive may be applied to the first surface 342 of thesecond substrate 308 before or while being joined with the first elasticstrands 318 and first substrate 306.

As previously discussed, the apparatus 300 includes the second pluralityof elastic strands 322 configured to replace the first plurality ofelastic stands 318 once the first beam 316 is completely depleted ornearly depleted of first elastic strands 318. As shown in FIGS. 19 and20, as the second beam 320 rotates, the second plurality of elasticstrands 322 advance from the second beam 320 at a speed V2 with thesecond elastic strands 322 being spaced apart from each other in thecross direction CD. In turn, leading ends 356 of the second plurality ofelastic strands 322 may be advanced onto the first roller 324 andbetween first substrate 306 and the second substrate 308. As such, thesecond plurality of elastic strands 322 are positioned in between thesecond surface 340 of the first substrate 306 and the first surface 342of the second substrate 308 such that the first plurality of elasticstrands 318, the second plurality of elastic strands 322, and the firstsubstrate 306 are positioned between the second substrate 308 and theouter circumferential surface 326 of the first roller 324. As discussedabove, the second plurality of elastic strands 322 may also be firstconnected with a splicer member 354. Thus, it is to be appreciated thatthe splicer member 354 and/or the second elastic strands 322 may beconnected with the first plurality of elastic strands 318, the firstsubstrate 306, or second substrate 308. As shown in FIGS. 19 and 20, theleading ends 356 of the second plurality of elastic strands 322 advancein the machine direction MD and are positioned on the second surface 340of the first substrate 306 on the first roller 324. And the secondsubstrate 306 advances to the first roller 324 to be combined with firstsubstrate 306, first elastic strands 318, and second elastic strands 322to form the elastomeric laminate 302. Once the second elastic strands322 are combined with the first substrate 306 and/or second substrate308, advancement of the first plurality of elastic strands 318 from thefirst beam 316 may be discontinued wherein trailing ends 358 of thefirst elastic strands 318 advance downstream to the first roller 324,such as shown in FIG. 21.

As shown in FIGS. 21 and 22, the apparatus 300 continues to operate toassemble the elastomeric laminate 302 with the second plurality ofelastics 322 advancing from the second beam 320. As the second beam 320rotates, the second plurality of elastic strands 322 advance from thesecond beam 320 at a speed V2 with the second elastic strands 322 beingspaced apart from each other in the cross direction CD. From the secondbeam 320, the second plurality of elastic strands 322 advances in themachine direction MD to the first roller 324 and are positioned on thesecond surface 340 of the first substrate 306. In some configurations,the speed V2 is less than the speed V1, and as such, the secondplurality of elastic strands 322 are stretched in the machine directionMD. In turn, the stretched second elastic strands 322 are joined withthe second surface 340 of the first substrate 306 and the first surface342 of the second substrate 308 to produce the continuous length ofelastomeric laminate 302 that advances from the first roller 324.

It is to be appreciated that in the various process configurationsdiscussed above, the second plurality of elastic strands 322 may befirst connected with a splicer member 354 before advancing the elasticstrands 322 in the assembly process. It is also to be appreciated thatin the various process configurations discussed above, the secondplurality of elastic strands 322 may be advanced directly into theassembly process without connecting the stands 322 to a splicer member.In some configurations, the second plurality of elastic strands 322 maybe connected or tied to each other with a knot before advancing into theassembly process. In some configurations, the first and/or secondsubstrate may have an electrostatic charge that attracts the strands 322to the substrates before advancing into assembly process. Further, insome configurations, strands 322 may be directed into the assemblyprocess by air flow, such as provided from a fan and/or a vacuum system.

As illustrated herein, the apparatuses and processes may be configuredsuch that elastic strands may be advanced from the beams and directly tothe assembly process without having to touch additional machinecomponents, such as for example, guide rollers. It is also to beappreciated that in some configurations, elastic strands may be advancedfrom the beams and may be redirected and/or otherwise touched by and/orredirected before advancing to the assembly process. For example, FIG.23 shows a configuration where the first beam rotation axis 346 mayextend in a first cross direction CD1. As the first beam 316 rotates,the first plurality of elastic strands 318 advance from the first beam316 in a first machine direction MD1 with the first elastic strands 318being spaced apart from each other in the first cross direction CD1. Theelastic strands 318 may then be redirected by rollers 321 from the firstmachine direction MD1 to a second machine direction MD2, wherein theelastic strands 318 may remain separated from each other in a secondcross direction CD2. From the rollers 321, the elastic strands 318 mayadvance in the second machine direction MD2 to be combined with thefirst and second substrates 306, 308 to form the elastic laminate 302.Thus, it is to be appreciated that the first and/or second beams 316,320 may be arranged and/or oriented such that the beam rotation axis346, 352 may be parallel, perpendicular, or otherwise angularly offsetwith respect to the machine direction advancement of the elasticlaminate 302 and/or the substrates 306, 308.

It is to be appreciated that a control system and/or an inspectionsystem may be utilized to control various aspects of the splicingoperations discussed herein. For example, as previously mentioned, thefirst beam 316 and the second beam 320 may be connected with one or moremotors, such as servo motors, to drive and control the rotation of thebeams 316, 320. As such, a control system may operate to control theacceleration and/or deceleration of the first and/or second beams 316,320 during the splicing operation to achieve and/or maintain the desiredtension in the elastic strands. In some configurations, the elasticstrands may be advanced from the beams 316, 320 through a series ofdancer rolls to help maintain desired tensions in the elastic strandsduring splicing operations. As previously mentioned, the elastomericlaminate 302 may also be subject to additional converting processes.Such additional converting processes may incorporate the elastomericlaminate 302 into discrete absorbent articles 100. As such, in someembodiments, an inspection system may be configured to detect and/ortrack a defective length of the elastomeric laminate 302. With referenceto FIG. 9, a defective length of elastomeric laminate 302 may be definedby a length of elastomeric laminate 302 that includes both the firstelastic strands 318 and the second elastic strands 322 positionedtogether between the first and second substrates 306, 308. A defectivelength of elastomeric laminate 302 may also be defined by a length ofelastomeric laminate 302 that includes the splicer member 354, leadingends 356 of the second elastic strands 322, and/or the trailing ends 358of the first elastic strands 318. The inspection system may alsocorrelate inspection results and measurements from the defect length ofthe elastomeric laminate 302 with absorbent articles 100 made therefrom.In turn, the inspection system may be used to control a reject system ona converting process of absorbent articles, wherein absorbent articlesmanufactured with portions of the defective length of elastomericlaminate 302 are rejected. In some configurations, defective articlesmay be subject to the rejection system and removed from the assemblyprocess. Absorbent articles 100 that are not deemed to be defective maybe subject to further processing steps, such as folding and packaging.In some configurations, an inspection system may be configured to detecta broken elastic strand advancing from a first beam 316. Upon detectionof a broken elastic strand, the inspection system may activate asplicing operation, such as described above, to place a second beam 320into service and remove the first beam 316 from service. In someconfigurations, an inspection and/or a control system may operate tocontrol the timing and placement of the splicer member 354 into theassembly operation, such as in the nip 336 shown in FIG. 4, which mayhelp an inspection system to more accurately track a splicing event. Itis to be appreciated that such an inspection system may be configured invarious ways, such as disclosed in U.S. Patent Publication No.2013/0199696 A1.

This application claims the benefit of U.S. Provisional Application No.62/436,589, filed on Dec. 20, 2016; 62/483,965, filed on Apr. 11, 2017;62/553,538, filed on Sep. 1, 2017; 62/553,149, filed on Sep. 1, 2017;62/553,171, filed on Sep. 1, 2017; and 62/581,278, filed on Nov. 3,2017, the entireties of which are all incorporated by reference herein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making an elastomeric laminate, themethod comprising steps of: providing a first plurality of elasticstrands wound onto a first beam; providing a second plurality of elasticstrands wound onto a second beam; rotating a first roller, the firstroller comprising an outer circumferential surface comprising a surfacespeed V1; rotating a second roller, the second roller comprising anouter circumferential surface comprising a surface speed V1, wherein thefirst roller and the second roller rotate in opposite directions, andwherein the first roller is adjacent the second roller to define a nipbetween the first roller and the second roller; advancing a firstsubstrate and a second substrate through the nip; unwinding the firstplurality of elastic strands from the first beam in a machine directionat a speed V2, wherein the first plurality of elastic strands areseparated from each other in a cross direction, and wherein V2 is lessthan V1; stretching the first plurality of elastic strands in themachine direction by advancing the first plurality of elastic strandsfrom the first beam through the nip and between the first substrate andthe second substrate; connecting the second plurality of elastic strandswith a splicer member; unwinding the second plurality of elastic strandsfrom the second beam in the machine direction, wherein the secondplurality of elastic strands are separated from each other in the crossdirection; advancing the splicer member and the second plurality ofelastic strands through the nip; connecting the splicer member with thefirst substrate subsequent to the step of connecting the secondplurality of elastic strands with the splicer member and prior to thestep of advancing the splicer member through the nip; and discontinuingadvancement of the first plurality of elastic strands through the nipsubsequent to advancing the splicer member through the nip.
 2. Themethod of claim 1, wherein the splicer member comprises a tacky surfaceand wherein the step of connecting the second plurality of elasticstrands with the splicer member further comprises adhering the tackysurface with the second plurality of elastic strands.
 3. The method ofclaim 1, further comprising a step of bonding the first substratetogether with the second substrate.
 4. The method of claim 1, furthercomprising a step of: applying adhesive to the first substrate.
 5. Themethod of claim 1, further comprising a step of applying adhesive to thefirst plurality of elastic strands.
 6. The method of claim 1, furthercomprising a step of stretching the second plurality of elastic strandsin the machine direction by advancing the second plurality of elasticstrands from the second beam through the nip between the first substrateand the second substrate.
 7. The method of claim 1, wherein the firstplurality of elastic strands comprises at least 50 elastic strands. 8.The method of claim 1, wherein the first plurality of elastic strandscomprises a decitex of less than
 1000. 9. A method for making anelastomeric laminate, the method comprising steps of: providing a firstplurality of elastic strands wound onto a first beam; providing a secondplurality of elastic strands wound onto a second beam; rotating a firstroller, the first roller comprising an outer circumferential surfacecomprising a surface speed V1; advancing a first substrate onto theouter circumferential surface of the first roller; unwinding the firstplurality of elastic strands from the first beam in a machine directionat a speed V2, wherein the first plurality of elastic strands areseparated from each other in a cross direction, and wherein V2 is lessthan V1; stretching the first plurality of elastic strands in themachine direction by advancing the first plurality of elastic strandsfrom the first beam onto the first substrate; advancing the combinedfirst substrate and the first plurality of elastic strands from thefirst roller; connecting the second plurality of elastic strands with asplicer member; unwinding the second plurality of elastic strands fromthe second beam, wherein the second plurality of elastic strands areseparated from each other in the cross direction; combining the splicermember and the second plurality of elastic strands with the firstplurality of elastic strands on the first substrate; connecting thesplicer member with the first substrate subsequent to the step ofconnecting the second plurality of elastic strands with the splicermember; and subsequently discontinuing advancement of the firstplurality of elastic strands onto the the first substrate.
 10. Themethod of claim 9, further comprising steps of: positioning a secondsubstrate in a facing relationship with the first substrate with thefirst plurality of elastic strands between the first substrate and thesecond substrate.
 11. The method of claim 10, further comprising stepsof: rotating a second roller about a second axis of rotation extendingin the cross direction, the second roller comprising an outercircumferential surface comprising a surface speed V1; and advancing thefirst surface of the second substrate onto the outer circumferentialsurface of the second roller.
 12. The method of claim 9, wherein thesplicer member comprises a tacky surface and wherein the step ofconnecting the second plurality of elastic strands with the splicermember further comprises adhering the tacky surface with the secondplurality of elastic strands.
 13. A method for making an elastomericlaminate, the method comprising steps of: providing a first plurality ofelastic strands wound onto a first beam; providing a second plurality ofelastic strands wound onto a second beam; rotating a roller, the rollercomprising an outer circumferential surface; providing a first substrateand a second substrate; advancing the first substrate onto the outercircumferential surface of the roller; unwinding the first plurality ofelastic strands from the first beam in a machine direction, wherein thefirst plurality of elastic strands are separated from each other in across direction; stretching the first plurality of elastic strands inthe machine direction while advancing the first plurality of elasticstrands from the first beam onto the first substrate; advancing thesecond substrate onto the first substrate such that the first pluralityof elastic strands and the first substrate are positioned between thesecond substrate and the outer circumferential surface of the roller;advancing the combined first substrate, second substrate, and the firstplurality of elastic strands from the roller; unwinding the secondplurality of elastic strands from the second beam, wherein the secondplurality of elastic strands are separated from each other in the crossdirection; advancing the second plurality of elastic strands in betweenthe first substrate and the second substrate such that the firstplurality of elastic strands, the second plurality of elastic strands,and the first substrate are positioned between the second substrate andthe outer circumferential surface of the roller; connecting the secondplurality of elastic strands with a splicer member; connecting thesplicer member with the first substrate subsequent to the step ofconnecting the second plurality of elastic strands with the splicermember; and subsequently discontinuing advancement of the firstplurality of elastic strands onto the first substrate.
 14. The method ofclaim 13, further comprising a step of: applying adhesive to the firstsubstrate.